Fluid dispersion unit with directional component vector

ABSTRACT

A valve-tray assembly and method for lighter fluid heavier fluid contact towers. The active area of the tray is constructed with valves having multiple lighter fluid discharge areas facilitating improved mass transfer efficiency. The valves include first and second support legs oriented in line with the heavier fluid flow with both legs and the valve top constructed with apertures wherein the heavier fluid may flow into engagement with the lighter fluid passing from beneath the tray up, through and out of the valve.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 12/408,333 (now U.S. Pat. No. 8,517,354), filed Mar. 20, 2009.U.S. patent application Ser. No. 12/408,333 claims priority from, andincorporates by reference for any purpose the entire disclosure of, U.S.Provisional Patent Application No. 61/038,067, filed Mar. 20, 2008. Thispatent application incorporates by reference for any purpose the entiredisclosure of U.S. patent application Ser. No. 12/408,333, filed Mar.20, 2009, U.S. patent application Ser. No. 12/109,781, filed Apr. 25,2008, and U.S. Provisional Patent Application No. 61/038,067, filed Mar.20, 2008.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to fluid-fluid contacting trays and, moreparticularly, but not by way of limitation, to an improved fluiddispersion device and tray assembly incorporating fixed and/or floatingunits having deflector tabs disposed across a tray for higher efficiencyoperation.

2. History of Related Art

It is well known to utilize distillation columns to separate selectedcomponents from a multicomponent stream. Generally, such contact columnsutilize either trays, packing, or combinations thereof. In certain yearsthe trend has been to replace so-called “bubble caps” by sieve and valvetrays in most tray column designs. Valve trays remain a favorabledesign.

Successful fractionation in the column is dependent upon intimatecontact between heavier fluids and lighter fluids. Some contact devices,such as trays, are characterized by relatively high pressure drop andrelatively high fluid hold-up. One type of contact apparatus utilizesfluid in the vapor phase to contact fluid in the liquid phase and hasbecome popular for certain applications. Another type of contactapparatus is high-efficiency packing, which is energy efficient becauseit has low pressure drop and low fluid hold-up. However, these veryproperties at times make columns equipped with structured packingdifficult to operate in a stable, consistent manner. Moreover, manyapplications simply require the use of trays.

Trays for fractionation columns are commonly designed in twoconfigurations: cross-flow and counter flow. The trays generally consistof a solid tray or deck having a plurality of apertures and areinstalled on support rings within the column. In cross-flow trays,lighter fluid ascends through the apertures and contacts heavier fluidmoving across the tray, through the “active” area thereof. In this area,the heavier fluid and the lighter fluid mix and fractionation occurs.The heavier fluid is directed onto the tray by means of a verticalchannel from the tray above. This channel is referred to as the InletDowncomer. The heavier fluid moves across the tray and exits through asimilar channel referred to as the Exit Downcomer. The location of thedowncomers determines the flow pattern of the heavier fluid. If thereare two Inlet Downcomers and the heavier fluid is split into two streamsover each tray, it is called a two pass tray. If there is only one Inletand one Outlet Downcomer on opposite sides of the tray, it is called asingle pass tray. For two or more passes, the tray is often referred toas a Multipass Tray. The number of passes generally increases as therequired (design) flow rate increases. It is the active area of thetray, however, which is of critical concern.

Addressing now select flow designs, a particularly effective tray inprocess columns is the sieve tray. This tray is constructed with a largenumber of apertures formed in the bottom surface. The apertures permitthe ascending lighter fluid to flow into direct engagement with theheavier fluid that is flowing across the tray from the downcomerdescribed above. When there is sufficient lighter-fluid flow upwardlythrough the tray, the heavier fluid is prevented from running downwardlythrough the apertures (referred to as “weeping”). A small degree ofweeping is normal in trays while a larger degree of weeping isdetrimental to the capacity and efficiency of a tray.

Tray efficiency is also known to be improved in sieve type trays byincreasing the froth height of the heavier fluid and reducing thebackflow of the heavier fluid flowing across the tray. Froth is createdwhen lighter fluid “bubbles” percolate upwardly through the heavierfluid flowing across the tray. The suspension of the lighter fluid inthe heavier fluid prolongs the fluid-fluid contact which enhances theefficiency of the process. The longer the froth is maintained and thehigher the froth is established, the greater the fluid-fluid retention.Higher froth requires smaller “bubbles” formed at a sufficiently slowrate. Likewise, backflow occurs beneath the froth when circulatingcurrents of heavier fluid are established during the heavier fluid flowacross the plate. This generally forms along the lateral portionsthereof. These currents carry the heavier fluid back across the tray ina manner that reduces the concentration-difference driving force formass transfer. It is the concentration-difference between the lighterfluid and the heavier fluid which enhances the effectiveness of thefluid-fluid contact.

The concentration-difference between the lighter fluid and the heavierfluid can be effected in many ways; some reducing efficiency. Forexample, as operating pressure increases, the heavier fluid begins toabsorb lighter fluid as it moves across a tray. This is above thatnormally dissolved in the heavier fluid and represents much largeramounts of lighter-fluid bubbles that are commingled or “entrained” withthe heavier fluid. This lighter fluid is not firmly held and is releasedwithin the downcomer, and, in fact, the majority of said lighter fluidmust be released otherwise the downcomer cannot accommodate the heavierfluid/lighter fluid mixture and will flood, thus preventing successfultower operation. This phenomena is generally deemed to occur whenoperating pressure is such as to produce a lighter fluid density aboveabout 1.0 lbs/cu. ft. and typically amounts to about 10 to 20% of thelighter fluid by volume. For conventional trays, as shown below, thereleased lighter fluid must oppose the descending frothy lighterfluid/heavier fluid mixture flowing over the weir into the downcomer. Inmany cases, such opposition leads to poor tower operation and prematureflooding.

When a vapor comprises the lighter fluid and a liquid comprises theheavier fluid, there are specific performance issues. Certainperformance and design issues are seen in the publication “DistillationTray Fundamentals”, M. J. Lockett, Cambridge University Press, 1986.Other examples are seen in several prior art patents, which include U.S.Pat. No. 3,338,566 issued to W. Kittel, U.S. Pat. No. 3,729,179 assignedto Fractionation Research, Inc., U.S. Pat. Nos. 3,282,576 and 4,275,021assigned to Union Carbide Corporation and U.S. Pat. No. 4,603,022 issuedto Mitsubishi Jukogyo Kabushiki Kaisha of Tokyo, Japan. A particularlyrelevant reference is seen in U.S. Pat. No. 4,499,035 assigned to UnionCarbide Corporation that teaches a gas-liquid contacting tray withimproved inlet bubbling means. A cross-flow tray of the type describedabove is therein shown with improved means for initiating bubbleactivity at the tray inlet comprising spaced apart, imperforate wallmembers extending substantially vertically upwardly and transverse tothe liquid flow path. The structural configuration is said to promoteactivity over a larger tray surface than that afforded by simpleperforated tray assemblies. This is accomplished in part by providing araised region adjacent the downcomer area for facilitating gas ascensiontherethrough.

U.S. Pat. No. 4,550,000 assigned to Shell Oil Company teaches anapparatus for contacting a liquid with a gas in a relationship betweenvertically stacked trays in a tower. The apertures in a given tray areprovided for the passage of gas in a manner less hampered by liquidcoming from a discharge means of the next upper tray. This is providedby perforated housings secured to the tray deck beneath the downcomersfor breaking up the descending liquid flow. Such advances in traydesigns improve efficiency within the confines of prior art structures.Likewise, U.S. Pat. No. 4,543,219 assigned to Nippon Kayaku KabushikiKaisha of Tokyo, Japan teaches a baffle-tray tower. The operationalparameters of high gas-liquid contact efficiency and the need for lowpressure loss are set forth. Such references are useful in illustratingthe need for high efficiency lighter fluid/heavier fluid contact in trayprocess towers. U.S. Pat. No. 4,504,426 issued to Karl T. Chuang et. al.and assigned to Atomic Energy of Canada Limited is yet another exampleof gas-liquid contacting apparatus.

Several prior patents have specifically addressed the tray design andthe apertures in the active tray deck area itself. For example, U.S.Pat. No. 2,787,453, a 1957 patent, and U.S. Pat. No. 2,853,281, a 1958patent, disclose directional tab-style fractionating trays that promotetray activity. By way of further example, U.S. Pat. No. 3,146,280 is a1964 patent teaching a directional float valve. The gas is induced todischarge from the inclined valve in a predefined direction depending onthe orientation of the valve in the tray deck. Such valve configurationsare often designed for particular applications and flow characteristics.Tray valves with weighted sides and various shapes have thus foundwidespread acceptance in the prior art. A circular valve structure isshown in U.S. Pat. No. 3,287,004 while a rectangular valve structure isshown in U.S. Pat. No. 2,951,691. Both of these patents issuing to I. E.Nutter, teach specific aspects of gas-liquid contact flow utilizing trayvalve systems. Such specialized designs are necessary because lighterfluid/heavier fluid flow problems must be considered for eachapplication in which a tray is fed by a downcomer. The type of flowvalve, its orientation, and the lighter-fluid flow apertures for lighterfluid-heavier fluid flow interaction are some of the issues addressed bythe present invention.

Addressing specifically now the type of flow valve, its orientation, andthe lighter-fluid flow apertures that currently are taught by the priorart. Attention is directed to two patents in which the inventors of thepresent application, Michael J. Binkley, is a co-inventor. U.S. Pat.Nos. 5,147,584 and 5,120,474, both teach certain valve-tray designs andcontact tray assemblies and methods. In the contact tray assemblies andthe valve designs, it may be seen that the individual valves whetherfixed or floating, are illustrated in the drawings with solid surfaces.In other words, both the front and rear legs, as well as the top surfaceof the valves, whether floating or fixed, are shown to be of solidconstruction. Other contact-tray valve assemblies are set forth andshown in U.S. Pat. Nos. 6,145,816; 5,911,922; 5,762,834; and 6,089,550.Each of these patents further illustrate aspects of contact trayassemblies and methods as well as valve designs. Additional patentswhich should likewise be reviewed relative to contact trays include thefollowing four patents in which the Applicant hereof, Michael J.Binkley, is a co-inventor and include: U.S. Pat. Nos. 5,453,222;4,956,127; 5,106,556; and 5,192,466. The above-referenced patents andstatements with regard to the related art are set forth for purposes ofunderstanding the intricacies of the design considerations incontact-tray assembly and method configurations. It would be anadvantage to provide a method of and apparatus for enhanced fluid flowmanifesting increased efficiency with a valve design having a deflectiontab in either a fixed or floating configuration relative to the tray forenhanced fluid interaction.

SUMMARY OF THE INVENTION

A tray valve assembly for a process column of a type wherein a first,heavier fluid flows downwardly from a downcomer onto a tray andthereacross in a first direction through which a second, lighter fluidflows upwardly therethrough for interaction and mass transfer with theheavier fluid before passing therefrom includes a plurality of trayapertures formed on a surface of the tray for facilitating the lighterfluid flow upwardly therethrough. The tray valve assembly furtherincludes a plurality of valves disposed across the surface of the trayand mounted in association with the plurality of tray apertures formedon the surface of the tray, at least one valve in the plurality ofvalves having one or more valve apertures to facilitate the lighterfluid flow therefrom and one or more deflector tabs. Each of the one ormore deflector tabs is disposed with one of the one or more valveapertures. The one or more deflector tabs and orientation of the atleast one valve on the tray allow ascending lighter fluid to be injectedinto the heavier fluid passing over the one or more valve apertures forpromoting directional flow of the heavier fluid therewith in at leastone direction.

A method of mixing a first, heavier fluid flowing downwardly from adowncomer onto a tray and thereacross in a first direction with asecond, lighter fluid flowing upwardly therethrough for interaction andmass transfer with the heavier fluid before passing therefrom, themethod includes forming, on a surface of the tray, a plurality of trayapertures for facilitating the lighter fluid flow upwardly therethroughand disposing, in association with the plurality of apertures formed onthe surface of the tray, a plurality of valves. The method furtherincludes forming, on at least one valve in the plurality of valves, oneor more valve apertures to facilitate the lighter fluid flow therefromand disposing, on the at least one valve, one or more deflector tabs.Each of the one or more deflector tabs is disposed with one of the oneor more valve apertures. The method additionally includes allowing, viathe one or more deflector tabs and an orientation of the at least onevalve on the tray, ascending lighter fluid to be injected into theheavier fluid passing over the one or more valve apertures to promotedirectional flow of the heavier fluid therewith in at least onedirection.

A valve for use in a tray valve assembly for a process column of a typewherein a first, heavier fluid flows downwardly from a downcomer onto atray and thereacross in a first direction through which a second,lighter fluid flows upwardly therethrough for interaction and masstransfer with the heavier fluid before passing therefrom includes abody, the body having a top surface and at least one securement leg. Thevalve further includes one or more valve apertures to facilitate thelighter fluid flow therefrom and one or more deflector tabs, each of theone or more deflector tabs being disposed with one of the one or morevalve apertures. The one or more deflector tabs and the one or morevalve apertures are adapted to allow ascending lighter fluid to beinjected into the heavier fluid passing over the one or more valveapertures for promoting directional flow of the heavier fluid therewithin at least one direction.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and forfurther objects and advantages thereof, reference may now be had to thefollowing description taken in conjunction with the accompanyingdrawings in which:

FIG. 1 illustrates a perspective view of a packed column with varioussections cut away for illustrating, diagrammatically, a variety of towerin accordance with an embodiment of the present invention;

FIG. 2 illustrates a diagrammatic, side-elevational, cross-sectionalview of a downcomer-tray assembly secured within a process tower andillustrating the flow of heavier fluid and lighter fluid thereacross inaccordance with an embodiment of the present invention;

FIG. 3 illustrates a top-plan, diagrammatic view of a tray illustratingefficiency problems with fluid flow transit in accordance with anembodiment of the present invention;

FIG. 4 illustrates a top plan view of a tray illustrating the flow offluid transit in accordance with an embodiment of the present invention;

FIG. 5A illustrates an enlarged, side elevation cross-sectional view ofa fixed unit of FIG. 4 in accordance with an embodiment of the presentinvention;

FIG. 5B illustrates an enlarged, side elevation cross-sectional view ofa fixed unit of FIG. 4 in accordance with an alternate embodiment of thepresent invention;

FIG. 6A illustrates a top plan view of the fixed unit structure of FIG.5A in accordance with an embodiment of the present invention;

FIG. 6B illustrates a top plan view of the fixed unit structure of FIG.5B in accordance with an alternate embodiment of the present invention;

FIG. 7 illustrates an enlarged perspective view of a floating unit inaccordance with an embodiment of the present invention; and

FIG. 8 illustrates a perspective view of an underneath side of analternative embodiment of the floating unit of FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring first to FIG. 1, there is shown a fragmentary, perspectiveview of an illustrative packed exchange tower or column with varioussections cut away for showing a variety of tower internals and theutilization of one embodiment of an improved high-capacity trayassembly. The exchange column 10 of FIG. 1 comprises a cylindrical tower12 having a plurality of packing bed layers 14 and trays disposedtherein. A plurality of manways 16 is likewise constructed forfacilitating access to the internal region of the tower 12. Alsoprovided are side stream draw-off line 20, heavier-fluid side feed line18, and side stream lighter-fluid feed line or reboiler return line 32.A reflux return line 34 is provided atop the column 10.

In operation, heavier fluid 13 is fed into the column 10 through refluxreturn line 34 and side stream feed-input feed line 18. The heavierfluid 13 flows downwardly through the tower and ultimately leaves thetower either at side stream draw-off line 20, or at bottom-streamdraw-off line 30. In the case of a vapor-liquid tower, the heavier fluid13, during its downward flow, is depleted of some material whichevaporate from it as it passes through the trays and packing beds, andis enriched or added to by material which condenses into it out of thelighter fluid stream.

Still referring to FIG. 1, the exchange column 10 is diagrammaticallycut in half for purposes of clarity. In this illustration, the column 10includes a lighter-fluid outlet in overhead line 26 disposed atop thetower 12 and a lower skirt 28 disposed in the lower region of the tower12 around bottom stream takeoff line 30 coupled to a reboiler (notshown). Reboiler return conduit 32 is shown disposed above the skirt 28for recycling lighter fluid therein upwardly through the trays and/orpacking layers 14. Reflux from condensers is provided in the upper towerregion 23 through entry conduit 34 wherein reflux is distributedthroughout a distributor 36 across upper packing bed 38. It may be seenthat the upper packing bed 38 is of the structured packing variety. Theregions of the exchange column 10 beneath the upper packing bed 38 areshown for the purpose of illustration and include a heavier fluidcollector 40 disposed beneath a support grid 41 in support of the upperstructured packing 38. The column 10 is presented with cut-line 43 forillustrating the fact that the tower internals arrangement isdiagrammatical only and is provided for referencing various componentarrays therein.

Referring still to FIG. 1, an assembly of a pair of trays is also shownfor purposes of illustration. In many instances, process columns containonly packing, only trays, or combinations of packing and trays. Thepresent illustration is, however, a combination for purposes ofdiscussion of the overall tower and its operation. A trayed columnusually contains a plurality of trays 48 of the type shown herein. Inmany instances, the trays 48 are valve or sieve trays. Valve trays,comprising the subject matter of the present invention, are hereinshown. Such trays comprise plates which are punched or slotted inconstruction. Within the scope of the invention and for the purposes ofthe description of various embodiments herein, the configurationreferred to as a “valve” or “unit” includes anything at the intersectionof and facilitating the dispersion contact between a lighter fluid and aheavier fluid. The lighter fluid and the heavier fluid engage at oralong the tray and, in some assemblies, are permitted to flow throughthe same openings in a counter-current flow arrangement. Optimally, thelighter-fluid and heavier-fluid flows reach a level of stability. Withthe utilization of appropriate downcomers, to be described in moredetail below, this stability may be achieved with a relatively low flowrate permitting the ascending lighter fluid to mix with the descendingheavier fluid. In some embodiments, no downcomers are used and thelighter fluid and the heavier fluid use the same openings, alternatingas the respective pressures change.

In the present embodiment, cross-flow valve trays 48 and 49 anddowncomers 53 and 69 are illustrated. Tray 48 is constructed with aplurality of floating valves. Tray 49 also illustrates a raised inletsection 51 beneath downcomer 53, which is substantially planar, formedwith a plurality of apertures, and which may include a series ofmomentum deflector barriers, as will be described below. The raisedinlet area is described in more detail in U.S. Pat. No. 4,956,127 (the'127 patent). Corrosion is another consideration in designing packedtowers and for the selection of the material, design, and thefabrication of the tower internals.

FIG. 2 illustrates a side-elevational, cross-sectional, diagrammaticview of the trays 48 and 49 of FIG. 1. An upper tray 48 comprises afirst valved panel. The lower tray 49 is also of generally planarconstruction across its central active area 52, having a plurality ofvalves 100 mounted thereon, disposed therein, or formed therefrom asdiagrammatically shown. Heavier fluid 13 travels down a downcomer 53having a straight, sloped, tapered or mitered bottom section 54, fromtray 48 disposed thereabove. The tapered section 54 of the downcomerprovides a clearance angle for lighter fluid flow from the active inletarea, which clearance angle affords a horizontal flow vector to thelighter fluid vented through a flat or raised panel 51. The heavierfluid 13 engages lighter fluid 15 discharged from the active panel area51 beneath the downcomer 53.

Still referring to FIG. 2, the froth 61 extends with a relativelyuniform height, shown in phantom by line 63 across the width of the tray49 to the opposite end 65 where a weir 67 is established for maintainingthe froth height 63. The accumulated froth at this point flows over thetop of the weir 67 into associated downcomer 69 that carries the frothdownwardly into a lower region 70 where the heavier fluid accumulatesand disperses upon active inlet region 71 therebeneath. Again activeinlet region 71 is shown herein diagrammatically for purposes ofillustration only. As stated herein, the area of holes and perforationsfor a single cross-flow plate establish the active length of the plateand the zone in which the froth 61 is established. It should be notedthat the present invention would also be applicable to multipledowncomer configurations, wherein the downcomers and raised, activeinlet areas may be positioned in intermediate areas of the trays as alsodescribed below. By increasing the total active area of active inletareas 51 and 71, greater capacity and efficiency is achieved. It is alsothe manner of flow of the heavier fluid 13 across the tray 49 which iscritical to tray efficiency.

FIG. 3 illustrates a flow diagram across a conventional tray. The priorart tray 72 is illustrated herein as a round unit having a firstconventional downcomer for feeding heavier fluid upon an underlyingpanel 73 and then to the tray 74. A second downcomer 74A carries heavierfluid away from the tray. A plurality of arrows 75 illustrates thenon-uniform flow of heavier fluid 13 typically observed across aconventional prior art tray which does not address the circulationissue. Circular flow is shown to be formed on both sides of the platelateral to the direction of primary flow. The formation of theseretrograde flow areas, or recirculation cells 76, decreases theefficiency of the tray. Recirculation cells 76 are the result ofretrograde flow near the walls of the process column and this backflowproblem becomes more pronounced as the diameter of the column increases.With the increase in retrograde flow and the resultant stagnation effectfrom the recirculation cells, concentration-difference driving force formass transfer between the counter-flowing streams is reduced. Thereduction in concentration-difference driving force will result in morecontact or height requirement for a given separation in the column.Although back mixing is but a single aspect of plate efficiency, thereduction thereof is provided concurrently with the other advantageshereof. Reference is again made to the plate efficiency discussion setforth in above referenced '127 patent.

FIG. 4 illustrates a top plan view of a tray 99 illustrating the flow ofheavier fluid 139 thereacross and the placement of a plurality of valves100 in accordance with principles of the present invention andillustrated with oppositely disposed regions A and B for placement ofdowncomer sections of the type shown in above-referenced U.S. Pat. No.5,120,474 (the '474 patent). Conventional materials such as stainlesssteel or other corrosion resistant material may be utilized, as is wellknown in the art. Each of the illustrated arrows corresponds to adirection of flow of the heavier fluid 139 as induced by one of theplurality of valves 100 that is mounted on the tray 99 at that location.For purposes of example, ones of the plurality of valves 100 are alsopictorially illustrated in inset 149.

Still referring to FIG. 4, the plurality of valves 100 is shownuniformly spread across tray 99. As will be more fully described below,the plurality of valves 100 can be formed in both “fixed” and “floating”configurations. In one embodiment, the plurality of valves 100 isuniformly disposed across the entire surface of tray 99. However,various other embodiments are contemplated where the pattern of theplurality of valves 100 is staggered or varied across a single tray 99.As will be described in more detail below, the heavier fluid 139,flowing across the tray 99, encounters a lighter fluid flowing upthrough the plurality of valves 100 for interaction therewith. Thedesign of the plurality of valves 100 is configured to increase theefficiency of that interaction. In various embodiments, the heavierfluid 139 may be, for example, fluid in the liquid phase and the lighterfluid may be, for example, fluid in the vapor phase.

Still referring to FIG. 4, the plurality of valves 100 is additionallyshown at various orientations relative to a direction of natural flow ofthe heavier fluid 139 from region A to region B. Through orientation, incombination with other novel characteristics of the plurality of valves100 to be discussed in more detail below, directional flow of theheavier fluid 139 may be induced. In some embodiments, directional flowmay be induced to provide momentum in the direction of natural flow ofthe heavier fluid. Directional flow may also be induced in a directionthat is different from the direction of natural flow. For example, alonga periphery of the tray 99, a turning flow of the heavier fluid 139 isshown to be induced. By way of further example, directional flow isshown to be induced orthogonally and at other angles relative to thenatural flow of the heavier fluid 139. Thus, through utilization of thevalves 100, directional flow of the heavier fluid 139 may besimultaneously induced in multiple directions. One of ordinary skill inthe art will recognize that many directions and angles relative to thenatural flow of the heavier fluid 139 are contemplated and may beadvantageous for specific applications.

FIGS. 5A-B illustrate an enlarged, side elevational cross-sectional viewof a fixed valve 100 of FIG. 4 in accordance with embodiments of thepresent invention. The fixed valve 100 of this embodiment is comprisedof a generally rectangular top surface 130 having angulated securementlegs 132 and 134 depending therefrom. The fixed valve 100 is fixedlymounted or formed within the surface of tray 99 and disposed above anaperture 136 formed therein. The orientation of the fixed valve 100relative to the fluid flow is shown by arrow 139.

Referring to FIG. 5A, it may be seen that the fixed valve 100 of thepresent invention includes a deflector tab 137 formed in the downstreamleg 132 thereof relative to fluid flow 139. The deflector tab 137 notonly deflects the flow of heavier fluid 139 across the tray 99 but alsoassists the momentum of the heavier fluid velocity by creating adeflector path for the rising lighter-fluid 142B ingressing in the samegeneral direction as the heavy fluid flow 139. The size of the fixedvalve 100 has been shown to be effective to date in the assembly of atray having an active area with approximately 25-50 valves per squarefoot. Other sizes are, of course, contemplated by the present invention.The deflector tab 137 controls a final injection angle as compared tomany prior art embodiments which inject the light fluid in a directionessentially orthogonal to the direction of heavy fluid flow. The presentinvention is thus a marked advance over many prior art designs. Theexemplary embodiment as illustrated in FIG. 5A includes only onedeflector tab 137; however, according to an alternate embodiment asillustrated in FIG. 5B, multiple deflector tabs 137A-C are shown.According to FIG. 5B, deflector tabs 137A-C may also be formed in thegenerally rectangular top surface 130 and/or in the upstream leg 134.According to alternate embodiments, tabs 137 may be located at severalother locations for different purposes. The light fluid kinetic energyis thus controlled to produce the desired heavy fluid vector results.

Still referring to FIGS. 5A-B, heavier-fluid flow is illustrated witharrow 139. As the heavier-fluid flow 139 engages the upstream leg member134 of the fixed valve 100, it is seen to partially split intotri-directional flow 141A and 141B traveling around the aperture 136;and 139 continuing over the generally rectangular top surface 130.Lighter fluid 140 venting beneath the fixed valve 100 is represented byarrows 142A, 142B, 142C, 142D, and 142E, which arrows illustrate thebiased direction that the lighter fluid 140 has in discharge frombeneath the valve 100. More particularly, it is shown in FIG. 5A how theheavier-fluid flow 139 interacts efficiently with the lighter-fluid flow140 due to the deflector tab 137 formed in the fixed valve 100. As shownherein and as described above, the fixed valve 100 is constructed withthe deflector tab 137 which deflects heavy fluid flow 139 and controlsthe final injection angle of the lighter fluid 140. The enhancedinteraction between the lighter-fluid flow 140 and the heavier fluidflow 139 is a key element in improved efficiency. The deflector tab 137may also be formed in a variety of shapes, angles, holes, sizes, andquantities.

Referring now to FIG. 5A, it may be seen that the orientation of thefixed valve 100 and the deflector tab 137 induces the lighter fluid flow142B to be in a direction substantially along the path of the heavierfluid flow 139 to further promote the directional flow of heavier fluid139. It should be noted that a “deflection tab turbulence” aspect of thefixed valve 100 further enhances the heavier fluid/lighter fluidinteraction. The deflector tab 137 causes interruption in the flow ofheavy fluid 139 to assist the injection and mixing of lighter fluid 140therewith.

FIG. 6A illustrates a top plan view of the fixed valve 100 of FIG. 5A inaccordance with an embodiment of the present invention. The upstream legmember 134 engages heavier-fluid flow 139 coming across the tray 99.Lighter fluid 140 ascending through the tray deck 99 is exhausted asrepresented by arrows 142A, 142B, and 142C. The escaping lighter fluidof arrows 142A through 142C interacts immediately with heavier fluidflow 139 and continues downstream of the leg member 132 having thedeflector tab 137 formed therein. It should be noted that the deflectortab 137 not only deflects the flow of heavier fluid 139 across the tray99 but also assists the momentum of the heavier fluid velocity bycreating a deflector path for the rising lighter-fluid 140 ingressing inthe same general direction as the heavy fluid flow 139.

FIG. 6B illustrates a top plan view of the fixed valve 100 of FIG. 5B inaccordance with an embodiment of the present invention. The upstream legmember 134 engages heavier-fluid flow 139 coming across the tray 99.Lighter fluid 140 ascending through the tray deck 99 is exhausted asrepresented by arrows 142A, 142B, 142C, 142D, and 142E. The escapinglighter fluid of arrows 142A through 142E interacts immediately withheavier fluid flow 139 and continues downstream of the leg member 132having the deflector tab 137A formed therein. It should be noted thatthe deflector tabs 137A-C not only deflects the flow of heavier fluid139 across the tray 99 but also assists the momentum of the heavierfluid velocity by creating a deflector path for the rising lighter-fluid140 ingressing in the same general direction as the heavy fluid flow139.

FIG. 7 illustrates an enlarged perspective view of a floating valve 200in accordance with an embodiment of the present invention. In thisembodiment, the floating valve 200 acts as a deflecting plate thatdeflects impinging fluid-flow across the tray 99 in order to disperserising lighter fluid 140 coming through the tray 99 into the heavierfluid stream 139 thereacross and is disposed in a generally rectangularaperture in the tray surface of FIG. 4. The floating valve 200 is, inthis embodiment, a separate structure inserted into tray 99. Thefloating valve 200 comprises securement legs 232 and 234 depending froma generally rectangular top surface 230. As shown, deflector tab 237A isformed on the securement leg 232 and two deflector tabs 237B are formedon the generally rectangular top surface 230.

According to an exemplary embodiment, the generally rectangular topsurface 230 of the floating valve 200 is wider than an aperture 236formed within the tray 99. The wider top 230 of the floating valve 200prevents the floating valve 200 from passing through the aperture 236.According to an exemplary embodiment, the securement leg 232 furthercomprises a generally rectangular tab 240 integrally connected to an endof the leg 232. The securement leg 234 further comprises a generallyrectangular tab 242 integrally connected to an end of the leg 234. Thegenerally rectangular tabs 240 and 242 secure the floating valve 200 tothe tray 99. The shape of securement legs 232 and 234 as illustrated inFIG. 7 is exemplary and other shapes and sizes may be utilized accordingto alternate embodiments. According to alternate embodiments, variousmeans for valve retention may be utilized such as, for example, aseparate retainer-cage mechanism having a separate floating disc as thevalve.

Still referring to FIG. 7, as the heavier-fluid flow 139 engages anupstream leg member 234 of the floating valve 200, it is seen topartially split into tri-directional flow 141A and 141B traveling aroundthe aperture 236; and 139 continuing over the generally rectangular topsurface 230. Lighter fluid 140 ascending through the tray deck 99 isexhausted as represented by arrows 142A, 142B, 142C, 142D, and 142E.More particularly, it is shown in FIG. 7 how the heavier-fluid flow 139interacts efficiently with the lighter-fluid flow 140 due to thedeflector tab 237A formed in the securement leg 232 and the deflectortabs 237B formed in the generally rectangular top surface 230.

FIG. 8 illustrates a perspective view of an underneath side of analternative embodiment of the floating valve 200. FIG. 8 furtherillustrates a fabrication of the floating valve 200 and itsconfiguration prior to placement of the valve 200 within the traysurface aperture. The upstream leg member 234 engages heavier-fluid flow139 coming across the tray 99. Lighter fluid 140 ascending through thetray deck 99 is exhausted as represented by arrows 142A, 142B, 142C,142D, and 142E. The escaping lighter fluid of arrows 142A through 142Einteracts immediately with heavier fluid flow 139 and continuesdownstream of the leg member 232 having the deflector tab 237A formedtherein. It should be noted that the deflector tabs 237A-C not onlydeflect the flow of heavier fluid 139 across the tray 99 but also assistthe momentum of the heavier fluid velocity by creating a deflector pathfor the rising lighter-fluid 140 ingressing in the same generaldirection as the heavy fluid flow 139.

In summary, this patent application is provided to further teach theutilization of both fixed and floating valves in a contact tray assemblythat is designed to enhance lighter fluid/heavier fluid interactionutilizing a multiplicity of valve and unit configurations. The contacttrays may have a plurality of valves and tabs of a multitude of shapes.The plurality of valves may have tabs of varying angles in order tocontrol the final injection angle. According to exemplary embodiments,the tabs maybe of various shapes such as, for example, rectangular,round and the like. In addition, according to various embodiments, theplurality of valves may be oriented at various angles relative to thenatural flow of the heavier fluid. Although exemplary embodimentsillustrate inducing directional flow in the direction of the naturalflow of the heavier fluid, it is contemplated that directional flow maybe induced in one or multiple directions as depicted, for example, inFIG. 4. Furthermore, although exemplary embodiments depict valves withsubstantially rectangular top surfaces, according to variousembodiments, the plurality of valves may be formed in a variety ofshapes. For example, it is contemplated that top surfaces of ones of theplurality of valves may be round or trapezoidal, which valve top surfaceshapes are disclosed in U.S. patent application Ser. No. 12/109,781,incorporated herein by reference. Other shapes, such as triangular, arealso contemplated and will be apparent to one of ordinary skill in theart.

It is thus believed that the operation and construction of the presentinvention will be apparent from the foregoing description. For themethod and apparatus shown or described has been characterized as beingpreferred it will be obvious that various changes and modifications maybe made therein without departing from the spirit and scope of theinvention as defined in the following claims.

Although various embodiments of the method and apparatus of the presentinvention have been illustrated in the accompanying Drawings anddescribed in the foregoing Detailed Description, it will be understoodthat the invention is not limited to the embodiments disclosed, but iscapable of numerous rearrangements, modifications and substitutionswithout departing from the spirit of the invention as set forth herein.

What is claimed is:
 1. A tray valve assembly for a process column of atype wherein a first, heavier fluid flows downwardly from a downcomeronto a tray and thereacross in a first direction through which a second,lighter fluid flows upwardly therethrough for interaction and masstransfer with the first, heavier fluid before passing therefrom, thetray valve assembly comprising: a plurality of tray apertures formed ona surface of the tray for facilitating the second, lighter fluid flowupwardly therethrough; a plurality of valves disposed across the surfaceof the tray and mounted in association with the plurality of trayapertures formed on the surface of the tray, at least one valve of theplurality of valves comprising: a top surface; a downstream securementleg coupled to the top surface; at least one valve aperture formed inthe downstream securement leg to facilitate the second, lighter fluidflow therefrom; a deflector tab disposed with the at least one valveaperture, the deflector tab being pivoted outwardly from the downstreamsecurement leg until the deflector tab is at least substantiallyparallel with the top surface, the deflector tab being pivoted about anupper edge of the at least one valve aperture; a second valve apertureformed on the top surface; a second deflector tab disposed with thesecond valve aperture; and the deflector tab and an orientation of theat least one valve on the tray allowing the second, lighter fluid to beinjected into the first, heavier fluid passing over the at least onevalve aperture for promoting directional flow of the first, heavierfluid therewith in at least one direction.
 2. The tray valve assembly ofclaim 1, wherein: the at least one valve in the plurality of valvesfurther comprises an upstream securement leg extending outwardly fromthe top surface; a third valve aperture is formed on the upstreamsecurement leg; and a third deflector tab, the third deflector tab isdisposed with the third valve aperture on the upstream securement leg.3. The tray valve assembly of claim 1 wherein the plurality of valvescomprise: a third valve aperture, the third valve aperture formed on thetop surface; and a third deflector tab disposed with the third valveaperture on the top surface.
 4. The tray valve assembly of claim 1,wherein the at least one direction is substantially parallel to thefirst direction.
 5. The tray valve assembly of claim 1, wherein the atleast one direction is oriented between 0 and 180 degrees relative tothe first direction.
 6. The tray valve assembly of claim 5, wherein theat least one direction is approximately orthogonal to the firstdirection.
 7. The tray valve assembly of claim 1, wherein the at leastone valve is a floating valve that is movably mounted within and overone of the plurality of tray apertures.
 8. The tray valve assembly ofclaim 1, wherein the deflector tab is adapted to allow flow of thefirst, heavier fluid in the first direction to be interrupted tofacilitate mixing of the second, lighter fluid therewith.
 9. The trayvalve assembly of claim 1, wherein the at least one valve in theplurality of valves comprises more than one of the plurality of valves.10. The tray valve assembly of claim 1, wherein the deflector tab issubstantially rectangular in shape.
 11. The tray valve assembly of claim1, wherein the deflector tab is substantially round in shape.
 12. Thetray valve assembly of claim 1, wherein the top surface is substantiallyrectangular in shape.
 13. The tray valve assembly of claim 1, whereinthe top surface is substantially round in shape.
 14. The tray valveassembly of claim 1, wherein the top surface is substantiallytrapezoidal in shape.
 15. A method of mixing a first, heavier fluidflowing downwardly from a downcomer onto a tray and thereacross in afirst direction with a second, lighter fluid flowing upwardlytherethrough for interaction and mass transfer with the first, heavierfluid before passing therefrom, the method comprising: forming, on asurface of the tray, a plurality of tray apertures for facilitating thesecond, lighter fluid flow upwardly therethrough; disposing, inassociation with the plurality of apertures formed on the surface of thetray, a plurality of valves, at least one valve of the plurality ofvalves comprising: a top surface; and a downstream securement legcoupled to the top surface: forming, in the downstream securement leg ofthe at least one valve of the plurality of valves, at least one valveaperture to facilitate the second, lighter fluid flow therefrom;disposing, on the downstream securement leg, a deflector tab disposedwith the at least one valve aperture and being pivoted outwardly fromthe downstream securement leg until the deflector tab is at leastsubstantially parallel with the top surface, the deflector tab beingpivoted about an upper edge of the at least one valve aperture; forming,in the top surface, a second valve aperture; disposing, with the secondvalve aperture, a second deflector tab; and allowing, via the deflectortab and an orientation of the at least one valve on the tray, thesecond, lighter fluid to be injected into the first, heavier fluidpassing over the at least one valve aperture to promote directional flowof the first, heavier fluid therewith in at least one direction.
 16. Themethod of claim 15, further comprising allowing, via the deflector tab,flow of the first, heavier fluid in the first direction to beinterrupted to facilitate mixing of the second, lighter fluid therewith.17. The method of claim 15, wherein: the at least one valve in theplurality of valves further comprises an upstream securement legextending outwardly from the top surface; the one or more valveapertures further comprise a third valve aperture, the third valveaperture being formed on the upstream securement leg; and the one ormore deflector tabs further comprise a third deflector tab, the thirddeflector tab being disposed with the third valve aperture on theupstream securement leg.
 18. The method of claim 15, wherein: the one ormore valve apertures further comprise a third valve aperture, the thirdvalve aperture being formed on the top surface; and the one or moredeflector tabs further comprise a third deflector tab, the thirddeflector tab being disposed with the third valve aperture on the topsurface.
 19. The method of claim 15, wherein the at least one directionis substantially parallel to the first direction.
 20. The method ofclaim 15, wherein the at least one direction is different from the firstdirection.
 21. The method of claim 15, wherein the at least one valve isa floating valve that is movably mounted within and over one of theplurality of tray apertures.
 22. The method of claim 15, wherein the atleast one valve in the plurality of valves comprises more than one ofthe plurality of valves.
 23. The method of claim 15, wherein thedeflector tab is substantially rectangular in shape.
 24. The method ofclaim 15, wherein the deflector tab is substantially round in shape. 25.A valve for use in a tray valve assembly for a process column of a typewherein a first, heavier fluid flows downwardly from a downcomer onto atray and thereacross in a first direction through which a second,lighter fluid flows upwardly therethrough for interaction and masstransfer with the first, heavier fluid before passing therefrom, thevalve comprising: a body comprising: a top surface; and a downstreamsecurement leg coupled to the top surface; at least one valve apertureformed in the downstream securement leg to facilitate the second,lighter fluid flow therefrom; a deflector tab disposed with the at leastone valve aperture and being pivoted outwardly from the downstreamsecurement leg until the deflector tab is at least substantiallyparallel with the top surface, the deflector tab being pivoted about anupper edge of the at least one valve aperture; a second valve apertureformed in the top surface; a second deflector tab disposed with thesecond valve aperture on the top surface; and the deflector tab and theat least one valve aperture being adapted to allow the second, lighterfluid to be injected into the first, heavier fluid passing over the atleast one valve aperture for promoting directional flow of the first,heavier fluid therewith in at least one direction.
 26. The valve ofclaim 25, comprising: a third valve aperture, the third valve aperturebeing formed on the top surface; and a third deflector tab, the thirddeflector tab being disposed with the third valve aperture on the topsurface.
 27. The valve of claim 25, comprising: an upstream securementleg extending outwardly from the top surface; a third valve aperture,the third valve aperture being formed on the upstream securement leg;and a third deflector tab, the third deflector tab being disposed withthe third valve aperture on the upstream securement leg.
 28. The valveof claim 25, wherein: the one or more valve apertures further comprise athird valve aperture, the third valve aperture being formed on the topsurface; and the one or more deflector tabs further comprise a thirddeflector tab, the third deflector tab being disposed with the thirdvalve aperture on the top surface.
 29. The valve of claim 25, whereinthe at least one valve is a floating valve.
 30. The valve of claim 25,wherein the deflector tab is adapted to allow the flow of the first,heavier fluid in the first direction to be interrupted to facilitatemixing of the second, lighter fluid therewith.
 31. The valve of claim25, wherein the deflector tab is substantially rectangular in shape. 32.The valve of claim 25, wherein the deflector tab is substantially roundin shape.
 33. The valve of claim 25, wherein the top surface issubstantially rectangular in shape.
 34. The valve of claim 25, whereinthe top surface is substantially round in shape.
 35. The valve of claim25, wherein the top surface is substantially trapezoidal in shape.